EP2934866B1 - Procédé pour fabriquer des structures géométriques complexes à partir de plusieurs pièces moulées - Google Patents

Procédé pour fabriquer des structures géométriques complexes à partir de plusieurs pièces moulées Download PDF

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Publication number
EP2934866B1
EP2934866B1 EP13817932.0A EP13817932A EP2934866B1 EP 2934866 B1 EP2934866 B1 EP 2934866B1 EP 13817932 A EP13817932 A EP 13817932A EP 2934866 B1 EP2934866 B1 EP 2934866B1
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EP
European Patent Office
Prior art keywords
parts
moulded parts
moulded
consolidation
shaping
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP13817932.0A
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German (de)
English (en)
Other versions
EP2934866A1 (fr
Inventor
Christopher BILBY
Dwight CHristopher CAMPBELL
Dustin Louis Dequine
Andrew LIZOTTE
David Russell CRAMER
D. Dewayne HOWELL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dieffenbacher GmbH Maschinen und Anlagenbau
Original Assignee
Dieffenbacher GmbH Maschinen und Anlagenbau
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Publication of EP2934866A1 publication Critical patent/EP2934866A1/fr
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Publication of EP2934866B1 publication Critical patent/EP2934866B1/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/261—Handling means, e.g. transfer means, feeding means
    • B29C51/262—Clamping means for the sheets, e.g. clamping frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/56—Tensioning reinforcements before or during shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/02—Combined thermoforming and manufacture of the preform
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/30—Moulds
    • B29C51/32—Moulds having cutting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/001—Layered products the layers being loose

Definitions

  • the present embodiments relate generally to thermoforming and in particular to thermoforming of long fiber-reinforced thermoplastics.
  • the embodiments relate to systems and methods for producing complex geometrical structures by connecting a plurality of final molded parts during and before forming.
  • thermoforming is a manufacturing process in which plastic is melted and then consolidated in a mold. It has many advantages over other manufacturing processes, as it is both simple and quick and can be implemented quickly.
  • thermoforming may have many advantages over other molding processes because it can be used to quickly produce thin-walled parts in a very efficient manner and thus has a relatively high production speed and lower tool costs, this process can be very complex and difficult for certain parts or part arrangements to produce complex parts of various shapes and sizes using standard die-cutting techniques. These parts often require post-processing or several steps, for example co-consolidation, isothermal forming or secondary assembly.
  • thermoformed LFRT parts can have advantages over other processes and Methods, such as injection molding, lose out when these parts become more complex and require multiple process steps to make parts.
  • thermoformed parts Current methods of manufacturing LFRT thermoformed parts include stamping, isothermal forming, co-consolidation, consolidation, and the traditional autoclave process, among others.
  • a decorative plate is known with a mounting plate which comprises a thermoplastic material and with an insert with a decorative surface and a thermoplastic carrier laminated to the decorative surface.
  • the insert is first connected to the decorative surface with the thermoplastic coating by heating, then shaped into any surface and finally pressed together with the mounting plate.
  • thermoforming From the FR 2 840 246 A1 a method for shaping and reinforcing a workpiece made of thermoplastic material is known, wherein first a layer of thermoplastic material is heated, placed in a mold and then subjected to thermoforming, and wherein a further layer of thermoplastic material is heated, placed in the mold and then with a counter tool molded in the mold and bonded to the first layer of thermoplastic material.
  • WO 2010/083840 A2 a method for producing a wind turbine blade is known, wherein in the production at least one layer of pre-impregnated fibers with an uncured thermosetting resin and at least one layer of hardened, fiber-reinforced resin are arranged at least partially overlapping, wherein after the layers have been arranged, the layer composite is jointly heated and is cured.
  • the embodiments provide methods and systems for producing complex geometric structures from multiple final molded parts during and prior to forming.
  • the embodiments provide methods and systems for producing complex parts from multiple net shape parts during or prior to forming.
  • the embodiments of the methods and systems can be created in multiple steps. These steps can be divided into three groups: (i) specific laying ("lay-up"); (ii) tailoring or trimming unconsolidated parts to final shape; and (iii) tension measures.
  • the present embodiments can result in a reduction in processing steps and enable complex structures to be formed relatively quickly.
  • the embodiments may also allow fiber-reinforced thermoplastic composite parts to be manufactured inexpensively and without compromising performance.
  • trimmed and consolidated moldings can be co-consolidated with unconsolidated moldings to produce parts that have features that resemble a metal plate that has been machined, for example, with a 3-axis machine tool.
  • the embodiments can be applied to all forms of thermoplastic matrices, such as, for example, PEEK, PEI, PEKK, nylon, PPS, and PP, and can also be applied to all types of reinforcing fibers, such as, for example, carbon fibers and glass fibers. Aspects of the embodiments can also be applied to thermoset composites such as carbon fiber and fiberglass epoxy, BMI, polyimide, and so on.
  • the present embodiments can result in a reduction in processing steps and enable complex structures to be formed relatively quickly.
  • Embodiments form a non-uniform or uniformly thick part into a desired shape by adjusting the design and processing of the raw molded part.
  • the Figure 1 illustrates the entire process for joining multiple final shape parts before or during forming.
  • the first step is the creation of the tailor-made raw molded parts or the non-consolidated LFRT molded parts from multiple layers of unidirectional tapes in a specific lay-up. This is best done with an understanding of how the thickness of continuous fiber thermoplastic parts changes as they are formed into complex shapes. Staging profiles, variations in density, or unevenly thick consolidated parts can result in a uniformly thick part, as in Figure 2 shown form.
  • the part can be placed in final shape or near net shape in preparation for consolidation; a corresponding example is the molded part 2 in Figure 3 , which schematically shows an example of a multi-thickness raw molded part, the stepped profiles ("ply-drop profiles"), the molded parts 1 and 2 in Figure 3 are shown as two separate parts, which, however, are fusion bonded during the consolidation of the mold parts 1 and 2.
  • the molded part 2, present in its final form, and the molded part 1 close to its final form are both tailored to a desired shape and can sometimes be trimmed from a bespoke near net shape part to a net shape part; which is the second step.
  • the molding 1 does not necessarily have to be a final molding because it may require unique clamping systems during molding. These clamping systems improve the quality of the final part by reducing the setbacks in the material properties due to part defects such as unevenness or bundling of material. This will be discussed in more detail below.
  • the molded parts 1 and 2 can be connected in a metal tool provided with pockets or recesses.
  • the consolidation controls the temperature of the parts and the tool under pressure.
  • the consolidation can produce a final molded part ready for deformation, a combination of a semi-finished final molded part fusion-bonded to an end molded part, or any combination of final molded parts, semi-finished final molded parts and near-net-shape parts.
  • the Figure 4 shows the molded part 2 as a final molded part on a molded part 1, as a semi-finished final molded part, ready for forming.
  • Figure 11 shows an exploded view of a lower mold 10 and an upper mold 12 corresponding to the lower mold 10, between which a molded part 11 is inserted.
  • Figure 12 it is shown how the molded part 11 is brought into the desired final shape by the lower mold 10 and the upper mold 12.
  • the reshaping takes place best when the molded part 2 or the final molded part is on the inner molding line of the part and is enclosed by the molded part 1, as in FIG Figure 6 shown.
  • Another embodiment forms end moldings onto end moldings during the stamping process by placing an end molding in the mold and molding a molten part thereon.
  • the molten part should be as hot as possible to create a fusion bond with the solidified part.
  • the preparation step for forming prepares the part for stamping thermoforming as in the Figures 7 to 10 shown.
  • the third step comprises the tensioning measures or the devices used for tensioning. These can be specific or individual, depending on the complexity of the shape, thickness and drawing depth.
  • the task of the clamping measures is to control the shape of the molded parts when the part is pulled into the mold and solidifies in the mold. The clamping measures induce a controlled and predictable movement of the material by reducing the pulling speed in the different sub-areas.
  • Tension can be applied in a variety of ways, but maintaining adhesion to molten parts is a challenge. This is best accomplished using aluminum heat shields, as in FIG Figures 8 to 10 with reference numerals 3, 4 and 5 denoting the bracket, the heat shield and the spring, respectively.
  • the heat shield 4 protects the molded part from the heat and thus prevents it from melting. This prevents the spring 5 and the clip 3 from being pulled out. This can also be promoted by supplying cold air to the heat shield if long dwell times or exposure times are required due to the part thickness and the need for a uniform part temperature.
  • the part is ready for individual stamping-thermoforming.
  • the part is manufactured in accordance with the method of the present embodiments and can be of a wide variety of shapes, sizes, thicknesses and designs.
  • the present embodiments can provide manufacturing methods that enable relatively rapid production of complex geometries consisting of LFTP. This enables parts to be produced without sacrificing production performance and structural integrity.
  • the present embodiments may provide manufacturing methods that enable parts to be manufactured that have features similar to those of a similar to machining (bumps or depressions, localized changes in thickness, radii on the edges of the bumps or depressions), as exemplified in Figure 13 shown.
  • thermoforming is performed by stamping thermoforming
  • this is not restrictive and the present invention can be applied to the production of parts in which only forming, for example by thermoforming, is necessary.
  • the present embodiments can also provide manufacturing methods that allow steps such as joining and trimming to be eliminated for the production of complex contours and shapes.
  • the present embodiments can also provide manufacturing methods that allow excellent and repeatable results with minimal human error.
  • the present embodiments can also provide manufacturing methods for forming complex structures that have minimal or no bumps, wrinkles, or clustered folded areas. When there are some bumps, wrinkles, or grouped creased areas, the present embodiments can enable the prediction, control, and limitation of bumps, creasing, and grouped creased areas.
  • the present embodiments may also reduce the number of manufacturing steps and thus the associated equipment wear and tear.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Claims (10)

  1. Procédé pour la fabrication de structures géométriques complexes à partir de plusieurs pièces moulées (1, 2), présentant les étapes consistant à :
    placer les pièces moulées (1, 2), au moins une pièce moulée (1, 2) étant réalisée à partir de plusieurs couches de bandes unidirectionnelles en thermoplastique renforcé de fibres longues,
    préparer les pièces moulées (1, 2) pour un moulage ;
    dans lequel, avant de préparer les pièces moulées (1, 2) pour un moulage, au moins une des pièces moulées (1, 2) est dressée ou mise à dimension à une forme finale ou proche d'une forme finale,
    dans lequel, avant de préparer les pièces moulées (1, 2) pour un moulage, au moins une pièce moulée en thermoplastique renforcé de fibres longues est soumise à une consolidation ; et
    mouler les pièces moulées (1, 2) préparées.
  2. Procédé selon la revendication 1, dans lequel
    au moins une première pièce moulée (1) est soumise à une consolidation et dressée ou mise à dimension à une forme finale ou proche d'une forme finale,
    au moins une deuxième pièce moulée (2) est mise à disposition sous la forme d'une pièce moulée non consolidée, et
    ladite au moins une première pièce moulée (1) consolidée et dressée ou mise à dimension est co-consolidée avec au moins une deuxième pièce moulée (2) non consolidée.
  3. Procédé selon l'une des revendications précédentes, dans lequel le moulage des pièces moulées préparées (1, 2) est effectué par thermoformage.
  4. Procédé selon la revendication 2, dans lequel le thermoformage est un formage, en particulier par thermoformage et découpage.
  5. Procédé selon l'une des revendications précédentes, dans lequel la préparation des pièces moulées (1, 2) pour le moulage comprend une application de mesures de serrage.
  6. Procédé selon la revendication 5, dans lequel l'application de mesures de serrage comprend la mise en place d'une pluralité d'unités de serrage, chaque unité de serrage présentant une pince (3), un bouclier thermique (4) et un ressort (5).
  7. Procédé selon la revendication 6, présentant en outre une amenée d'air froid au bouclier thermique (4).
  8. Procédé selon l'une des revendications précédentes, dans lequel les pièces moulées (1, 2) sont liées par fusion pendant la consolidation.
  9. Procédé selon l'une des revendications précédentes, dans lequel la consolidation est réalisée sous pression.
  10. Procédé selon l'une des revendications précédentes, dans lequel la température des pièces moulées (1, 2) et des outils est commandée pendant la consolidation.
EP13817932.0A 2012-12-21 2013-12-20 Procédé pour fabriquer des structures géométriques complexes à partir de plusieurs pièces moulées Active EP2934866B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201261740491P 2012-12-21 2012-12-21
US201261740700P 2012-12-21 2012-12-21
PCT/EP2013/077781 WO2014096403A1 (fr) 2012-12-21 2013-12-20 Procédé pour fabriquer de structures géométriques complexes à partir de plusieurs pièces moulées

Publications (2)

Publication Number Publication Date
EP2934866A1 EP2934866A1 (fr) 2015-10-28
EP2934866B1 true EP2934866B1 (fr) 2020-10-14

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EP13817932.0A Active EP2934866B1 (fr) 2012-12-21 2013-12-20 Procédé pour fabriquer des structures géométriques complexes à partir de plusieurs pièces moulées

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WO (1) WO2014096403A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3031109B1 (fr) 2014-12-24 2018-08-17 Arkema France Composition de polymeres, son procede de preparation, son utilisation et composition la comprenant

Family Cites Families (6)

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Publication number Priority date Publication date Assignee Title
US5462786A (en) * 1991-03-22 1995-10-31 Asaa Technologies, Inc. Decorative panels for automobile interiors
DE4441986C2 (de) * 1994-11-25 1996-12-05 Reiss Int Gmbh Verfahren zur Herstellung eines kaschierten Formteils
AU2001280861A1 (en) 2000-07-28 2002-02-13 Hypercar, Inc. Process and equipment for manufacture of advanced composite structures
FR2840246B1 (fr) * 2002-05-28 2005-05-20 Chomarat Composites Nouveau procede de mise en forme et de renforcement de pieces thermoplastiques
US8048253B2 (en) 2007-09-26 2011-11-01 Fiberforge Corporation System and method for the rapid, automated creation of advanced composite tailored blanks
WO2010083840A2 (fr) * 2009-01-21 2010-07-29 Vestas Wind Systems A/S Procédé de fabrication d'une pale d'éolienne par intégration d'une couche de résine durcie au préalable renforcée par des fibres

Non-Patent Citations (1)

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WO2014096403A1 (fr) 2014-06-26
EP2934866A1 (fr) 2015-10-28

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